Kawasaki Wheel Loader ZX350 7 Operational & Service Manual & Parts Manual
File Details:
Kawasaki Wheel Loader ZX350 7 Operational & Service Manual & Parts Manual
Language : English
Pages : 500+
Size : 188 MB
Downloadable : Yes
Format : PDF
Video Preview:
Image Preview:
Table of Contents:
Kawasaki Wheel Loader ZX350 7 Operational & Service Manual & Parts Manual
Diagnosing Procedure………………………..T5-1-1
Introduction…………………………………………………………………T5-1-1
Diagnosis Procedure…………………………………………………..T5-1-2
Electrical System Inspection……………………………………..T5-1-5
Precautions for Inspection and Maintenance…………T5-1-5
Instructions for Disconnecting Connectors……………T5-1-7
Instructions for Removing Relays…………………………….T5-1-9
Fuse Inspection………………………………………………………….T5-1-11
Fuse Connection Destination………………………………….T5-1-11
Fusible Link Inspection…………………………………………….T5-1-13
Battery Voltage Check………………………………………………T5-1-17
Alternator Check……………………………………………………….T5-1-17
Continuity Check………………………………………………………T5-1-19
Voltage and Current Measurement of 24-Volt Circuit……………………………………………………………………..T5-1-20
Voltage and Current Measurement of 5-Volt Circuit……………………………………………………………………..T5-1-26
Check by False Signal……………………………………………….T5-1-29
Test Wire Harness………………………………………………………T5-1-30
Removal of ECM………………………………………………………..T5-1-31
Installation of ECM……………………………………………………T5-1-33
Removal of DCU………………………………………………………..T5-1-35
Installation of DCU……………………………………………………T5-1-37
Removal of MC (Main Controller)……………………………T5-1-38
Installation of MC (Main Controller)……………………….T5-1-41
Removal of Monitor Controller……………………………….T5-1-44
Installation of Monitor Controller…………………………..T5-1-47
Removal of GSM………………………………………………………..T5-1-51
Installation of GSM……………………………………………………T5-1-54
Removal of PLCU (Option)……………………………………….T5-1-58
Installation of PLCU (Option)…………………………………..T5-1-61
Removal of Aerial Angle Controller………………………..T5-1-64
Installation of Aerial Angle Controller……………………T5-1-67
Mounting Position of Pump Delivery Pressure Sensor…………………………………………………………………….T5-1-70
Mounting Position of Pump Control Pressure Sensor…………………………………………………………………….T5-1-71
Mounting Position of Boom Raise Pilot Pressure Sensor…………………………………………………………………….T5-1-72
Mounting Position of Arm Roll-Out Pilot Pressure Sensor…………………………………………………………………….T5-1-72
Mounting Position of Arm 2 Roll-In Pilot Pressure Sensor…………………………………………………………………….T5-1-73
Mounting Position of Bucket Roll-Out Pilot Pressure Sensor…………………………………………………….T5-1-73
Mounting Position of Bucket Roll-In Pilot Pressure Sensor…………………………………………………………………….T5-1-74
Mounting Position of Travel Pilot Pressure Sensor………………………………………………………………………………….T5-1-74
Mounting Position of Arm 1 Roll-In Pilot Pressure Sensor…………………………………………………………………….T5-1-75
Mounting Position of Swing Pilot Pressure Sensor………………………………………………………………………………….T5-1-75
Mounting Position of Front Pilot Pressure Sensor…………………………………………………………………………………..T5-1-76
Mounting Position of Auxiliary 1 Pilot Pressure Sensor…………………………………………………………………….T5-1-76
Mounting Position of Auxiliary 2 Pilot Pressure Sensor…………………………………………………………………….T5-1-77
Mounting Position of Fuel Sensor…………………………..T5-1-78
Mounting Position of Hydraulic Oil Temperature Sensor…………………………………………………………………….T5-1-78
Mounting Position of Differential Differential Differential Pressure Sensor………………………………………………………………………………….T5-1-79
Mounting Position of Exhaust Temperature Sensor…………………………………………………………………….T5-1-79
Mounting Position of NOx Sensor………………………….T5-1-80
Mounting Position of Engine Oil Monitoring Sensor…………………………………………………………………….T5-1-80
Mounting Position of Hydraulic Oil Monitoring Sensor…………………………………………………………………….T5-1-81
Mounting Position of Ambient Temperature Sensor…………………………………………………………………….T5-1-82
Mounting Position of Re-circulated Air Temperature Sensor…………………………………………….T5-1-82
Mounting Position of Frost Sensor…………………………T5-1-83
Mounting Position of Solar Radiation Sensor……….T5-1-83
Monitor………………………………………………T5-2-1
Basic Screen of Monitor……………………………………………..T5-2-1
Operating Procedures of Service Menu…………………..T5-2-1
How to Display Service Menu…………………………………..T5-2-2
How to Display Troubleshooting Screen…………………T5-2-4
How to Display Monitoring……………………………………….T5-2-7
Monitoring Items of Engine Controller (ECM)………T5-2-11
Monitoring Items of Main Controller (MC)……………T5-2-13
Monitoring Items of PLCU……………………………………….T5-2-18
Monitoring Items of Monitor Controller (Information)…………………………………………………………T5-2-18
Monitoring Items of Switch Box Controller…………..T5-2-19
Monitoring Items of Air Conditioner Unit……………..T5-2-20
TTDD750-EN-00(22/01/2020)
How to Display Controller Version………………………….T5-2-20
How to Display Operation……………………………………….T5-2-21
How to Display Communication Terminal Status……………………………………………………………………………………T5-2-23
List of Communication Terminal Status…………………T5-2-24
Operating Procedures of Breaker Alarm………………..T5-2-25
Operating Procedures of Machine Setting (Constant Change)……………………………………………….T5-2-27
List of Machine Setting Items………………………………….T5-2-30
Operating Procedures of Monitor Setting (Operation Permission)……………………………………….T5-2-32
Operating Procedures of Monitor Setting (Maintenance Items)……………………………………………T5-2-35
List of Monitor Setting Items…………………………………..T5-2-38
Operating Procedures of Attachment Setting (Constant Change)……………………………………………….T5-2-40
List of Attachment Setting Items……………………………T5-2-43
Operating Procedures of Engine Setting………………T5-2-46
How to Display Aftertreatment Device No……………T5-2-48
Attachment Adjustment………………………………………….T5-2-50
Operating Procedures of Breaker Relief Pressure…………………………………………………………………………………….T5-2-50
Operating Procedures of Auxiliary Overload Relief Valve Pressure……………………………………………………….T5-2-54
Inspection of Engine Oil Level and Coolant Level……………………………………………………………………………………T5-2-57
Inspection of Hour Meter and Fuel Gauge……………T5-2-58
Fuel Gauge…………………………………………………………………T5-2-59
Coolant Temperature Gauge…………………………………..T5-2-60
DEF Gauge………………………………………………………………….T5-2-60
Hydraulic Oil Temperature Gauge………………………….T5-2-61
e-Service…………………………………………….T5-3-1
Outline of e-Service……………………………………………………T5-3-1
List of Operation Data………………………………………………..T5-3-1
Communication System…………………………………………….T5-3-3
Component Layout……………………………..T5-4-1
Main Component (Upperstructure)…………………………T5-4-1
Main Component (Undercarriage)…………………………..T5-4-3
Main Component (Front Attachment)…………………….T5-4-3
Electrical System (Overview)…………………………………….T5-4-4
Electrical System (Rear Tray)……………………………………..T5-4-5
Electrical System (Switches)………………………………………T5-4-6
Electrical System (Utility Space)……………………………….T5-4-7
Electrical System (Relays)…………………………………………..T5-4-8
Engine Oil Monitoring Sensor…………………………………..T5-4-8
Hydraulic Oil Monitoring Sensor………………………………T5-4-9
Engine…………………………………………………………………………T5-4-10
Aftertreatment Device……………………………………………..T5-4-11
Pump Device……………………………………………………………..T5-4-12
Around Pump Device……………………………………………….T5-4-12
Control Valve……………………………………………………………..T5-4-13
Signal Control Valve………………………………………………….T5-4-13
Swing Device……………………………………………………………..T5-4-14
Travel Device……………………………………………………………..T5-4-15
5-Spool Solenoid Valve Unit……………………………………T5-4-15
3-Spool Solenoid Valve Unit……………………………………T5-4-16
2-Spool Solenoid Valve Unit (For Aftertreatment Device Regeneration Control)……………………………T5-4-16
DEF Tank……………………………………………………………………..T5-4-17
DEF Supply Module…………………………………………………..T5-4-17
Layout of Attachment Spec. Parts………………………….T5-4-18
Around Control Valve……………………………………………….T5-4-19
Control Valve Lower Side…………………………………………T5-4-19
Utility Space……………………………………………………………….T5-4-20
Components in Control Valve…………………………………T5-4-21
Pilot Valve Side of Pilot Port…………………………………….T5-4-40
Control Valve Side of Pilot Port……………………………….T5-4-42
Port Layout of Control Valve (Main Circuit)…………..T5-4-44
Port Layout of Control Valve (Pilot Circuit)……………T5-4-46
Cab Harness……………………………………………………………….T5-4-49
Main Harness……………………………………………………………..T5-4-59
Pump Harness……………………………………………………………T5-4-68
NOx Harness………………………………………………………………T5-4-69
Monitor Harness………………………………………………………..T5-4-70
Console Harness………………………………………………………..T5-4-71
Control Valve Harness………………………………………………T5-4-73
Wiper Harness……………………………………………………………T5-4-75
Wiper Motor Harness………………………………………………..T5-4-76
Pilot Shut-Off Shut-OffShut-OffShut-Off Solenoid Valve Harness…………………..T5-4-77
Engine Stop Switch Harness……………………………………T5-4-78
Cigar Lighter Sub Harness……………………………………….T5-4-79
Connector Layout of MC………………………………………….T5-4-79
Connector Layout of Monitor Controller……………….T5-4-81
Connector Layout of ECM………………………………………..T5-4-82
Connector Layout of DCU………………………………………..T5-4-82
Connector Layout of GSM ……………………………………….T5-4-83
Connector Layout of Aerial Angle Controller……….T5-4-83
Connector Layout of PLCU (Option)………………………T5-4-84
Troubleshooting A………………………………T5-5-1
Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Procedure………………………………T5-5-1
Contents of Troubleshooting A………………………………..T5-5-1
MC Fault Code 73000-3………………………………………………T5-5-2
MC Fault Code 73000-4………………………………………………T5-5-4
MC Fault Code 73001-3………………………………………………T5-5-6
MC Fault Code 73001-4………………………………………………T5-5-7
MC Fault Code 73002-3………………………………………………T5-5-7
MC Fault Code 73003-2………………………………………………T5-5-8
MC Fault Code 73004-2………………………………………………T5-5-8
MC Fault Code 73005-2………………………………………………T5-5-8
MC Fault Code 73006-2………………………………………………T5-5-9
MC Fault Code 41000-2………………………………………………T5-5-9
MC Fault Code 51000-3…………………………………………….T5-5-10
MC Fault Code 51000-4…………………………………………….T5-5-11
MC Fault Code 51001-3…………………………………………….T5-5-12
MC Fault Code 51001-4…………………………………………….T5-5-13
MC Fault Code 51002-3…………………………………………….T5-5-13
MC Fault Code 51002-4…………………………………………….T5-5-14
MC Fault Code 51003-3…………………………………………….T5-5-15
TTDD750-EN-00(22/01/2020)
MC Fault Code 51003-4…………………………………………….T5-5-16
MC Fault Code 51004-3…………………………………………….T5-5-16
MC Fault Code 51004-4…………………………………………….T5-5-17
MC Fault Code 51005-3…………………………………………….T5-5-18
MC Fault Code 51005-4…………………………………………….T5-5-19
MC Fault Code 53000-3…………………………………………….T5-5-19
MC Fault Code 53000-4…………………………………………….T5-5-20
MC Fault Code 53001-3…………………………………………….T5-5-21
MC Fault Code 53001-4…………………………………………….T5-5-22
MC Fault Code 53002-3…………………………………………….T5-5-22
MC Fault Code 53002-4…………………………………………….T5-5-23
MC Fault Code 53003-3…………………………………………….T5-5-24
MC Fault Code 53003-4…………………………………………….T5-5-25
MC Fault Code 53004-3…………………………………………….T5-5-26
MC Fault Code 53004-4…………………………………………….T5-5-27
MC Fault Code 53005-3…………………………………………….T5-5-27
MC Fault Code 53005-4…………………………………………….T5-5-28
MC Fault Code 53006-3…………………………………………….T5-5-29
MC Fault Code 53006-4…………………………………………….T5-5-30
MC Fault Code 53015-3…………………………………………….T5-5-30
MC Fault Code 53015-4…………………………………………….T5-5-31
MC Fault Code 53016-3…………………………………………….T5-5-32
MC Fault Code 53016-4…………………………………………….T5-5-33
MC Fault Code 51006-2…………………………………………….T5-5-33
MC Fault Code 51006-6…………………………………………….T5-5-34
MC Fault Code 51006-5…………………………………………….T5-5-35
MC Fault Code 51007-2…………………………………………….T5-5-35
MC Fault Code 51007-6…………………………………………….T5-5-36
MC Fault Code 51007-5…………………………………………….T5-5-37
MC Fault Code 51008-2…………………………………………….T5-5-37
MC Fault Code 51008-6…………………………………………….T5-5-38
MC Fault Code 51008-5…………………………………………….T5-5-39
MC Fault Code 51009-2…………………………………………….T5-5-39
MC Fault Code 51009-6…………………………………………….T5-5-40
MC Fault Code 51009-5…………………………………………….T5-5-41
MC Fault Code 51010-2…………………………………………….T5-5-41
MC Fault Code 51010-6…………………………………………….T5-5-42
MC Fault Code 51010-5…………………………………………….T5-5-42
MC Fault Code 51011-2…………………………………………….T5-5-43
MC Fault Code 51011-6…………………………………………….T5-5-44
MC Fault Code 51011-5…………………………………………….T5-5-44
MC Fault Code 51012-2…………………………………………….T5-5-45
MC Fault Code 51012-6…………………………………………….T5-5-46
MC Fault Code 51012-5…………………………………………….T5-5-46
MC Fault Code 51013-2…………………………………………….T5-5-47
MC Fault Code 51013-6…………………………………………….T5-5-48
MC Fault Code 51013-5…………………………………………….T5-5-48
MC Fault Code 51014-2…………………………………………….T5-5-49
MC Fault Code 51014-6…………………………………………….T5-5-50
MC Fault Code 51014-5…………………………………………….T5-5-50
MC Fault Code 51015-2…………………………………………….T5-5-51
MC Fault Code 51015-6…………………………………………….T5-5-51
MC Fault Code 51015-5…………………………………………….T5-5-52
MC Fault Code 51016-2…………………………………………….T5-5-53
MC Fault Code 51016-6…………………………………………….T5-5-53
MC Fault Code 51016-5…………………………………………….T5-5-54
MC Fault Code 51017-2…………………………………………….T5-5-55
MC Fault Code 51017-6…………………………………………….T5-5-55
MC Fault Code 51017-5…………………………………………….T5-5-56
MC Fault Code 51018-2…………………………………………….T5-5-56
MC Fault Code 51018-6…………………………………………….T5-5-57
MC Fault Code 51018-5…………………………………………….T5-5-57
MC Fault Code 51019-2…………………………………………….T5-5-57
MC Fault Code 51019-6…………………………………………….T5-5-58
MC Fault Code 51019-5…………………………………………….T5-5-59
MC Fault Code 51020-2…………………………………………….T5-5-59
MC Fault Code 51021-3…………………………………………….T5-5-60
MC Fault Code 51021-4…………………………………………….T5-5-61
MC Fault Code 51022-3…………………………………………….T5-5-62
MC Fault Code 51022-4…………………………………………….T5-5-62
MC Fault Code 51023-3…………………………………………….T5-5-63
MC Fault Code 51023-4…………………………………………….T5-5-64
MC Fault Code 51025-0…………………………………………….T5-5-64
MC Fault Code 51026-14………………………………………….T5-5-65
MC Fault Code 63000-2…………………………………………….T5-5-65
MC Fault Code 73007-2…………………………………………….T5-5-65
MC Fault Code 73008-2…………………………………………….T5-5-66
MC Fault Code 73034-2…………………………………………….T5-5-66
MC Fault Code 51029-2…………………………………………….T5-5-66
MC Fault Code 51029-6…………………………………………….T5-5-67
MC Fault Code 51029-5…………………………………………….T5-5-68
MC Fault Code 51030-2…………………………………………….T5-5-68
MC Fault Code 51030-6…………………………………………….T5-5-69
MC Fault Code 51030-5…………………………………………….T5-5-70
MC Fault Code 51031-2…………………………………………….T5-5-70
MC Fault Code 51031-6…………………………………………….T5-5-71
MC Fault Code 51031-5…………………………………………….T5-5-72
MC Fault Code 73028-2…………………………………………….T5-5-72
Monitor Controller (Information) Fault Code 41001-2………………………………………………………………….T5-5-73
Monitor Controller (Information) Fault Code 41002-3………………………………………………………………….T5-5-73
Monitor Controller (Information) Fault Code 41003-3………………………………………………………………….T5-5-74
Monitor Controller (Information) Fault Code 41003-4………………………………………………………………….T5-5-75
Monitor Controller (Information) Fault Code 73033-2………………………………………………………………….T5-5-76
Monitor Controller (Information) Fault Code 41004-14………………………………………………………………..T5-5-77
Monitor Controller (Information) Fault Code 41005-14………………………………………………………………..T5-5-77
Monitor Controller (Information) Fault Code 41006-14………………………………………………………………..T5-5-78
Monitor Controller (Information) Fault Code 41007-14………………………………………………………………..T5-5-78
Monitor Controller (Information) Fault Code 41008-14………………………………………………………………..T5-5-78
Monitor Controller (Information) Fault Code 41004-20………………………………………………………………..T5-5-79
Monitor Controller (Information) Fault Code 73013-2………………………………………………………………….T5-5-79
TTDD750-EN-00(22/01/2020)
Monitor Controller (Information) Fault Code 73014-2………………………………………………………………….T5-5-80
Monitor Controller (Information) Fault Code 73015-2………………………………………………………………….T5-5-80
Monitor Controller (Information) Fault Code 73016-2………………………………………………………………….T5-5-80
Monitor Controller (Information) Fault Code 73017-2………………………………………………………………….T5-5-81
Monitor Controller (Information) Fault Code 73018-2………………………………………………………………….T5-5-81
Monitor Controller (Information) Fault Code 73019-2………………………………………………………………….T5-5-82
Monitor Controller (Information) Fault Code 73020-2………………………………………………………………….T5-5-82
Monitor Controller (Information) Fault Code 73021-2………………………………………………………………….T5-5-83
Monitor Controller (Information) Fault Code 68004-12………………………………………………………………..T5-5-83
Monitor Controller (Information) Fault Code 68005-12………………………………………………………………..T5-5-83
Monitor Controller (Information) Fault Code 68006-12………………………………………………………………..T5-5-83
Monitor Controller (Information) Fault Code 68007-12………………………………………………………………..T5-5-84
Monitor Controller (Information) Fault Code 68008-12………………………………………………………………..T5-5-84
Monitor Controller (Information) Fault Code 68009-12………………………………………………………………..T5-5-84
Monitor Controller (Information) Fault Code 41002-4………………………………………………………………….T5-5-84
Monitor Controller (Information) Fault Code 73029-2………………………………………………………………….T5-5-85
Monitor Controller (Monitor) Fault Code 73010-2…………………………………………………………………………………..T5-5-85
Monitor Controller (Monitor) Fault Code 73011-2…………………………………………………………………………………..T5-5-85
Monitor Controller (Monitor) Fault Code 73012-2…………………………………………………………………………………..T5-5-86
Monitor Controller (Monitor) Fault Code 73030-2…………………………………………………………………………………..T5-5-86
Monitor Controller (Monitor) Fault Code 13911-3…………………………………………………………………………………..T5-5-87
Monitor Controller (Monitor) Fault Code 13912-4…………………………………………………………………………………..T5-5-87
Monitor Controller (Monitor) Fault Code 13913-3…………………………………………………………………………………..T5-5-88
Monitor Controller (Monitor) Fault Code 13914-4…………………………………………………………………………………..T5-5-89
Monitor Controller (Monitor) Fault Code 13917-3…………………………………………………………………………………..T5-5-89
Monitor Controller (Monitor) Fault Code 13918-4…………………………………………………………………………………..T5-5-90
Monitor Controller (Monitor) Fault Code 13921-3…………………………………………………………………………………..T5-5-90
Monitor Controller (Monitor) Fault Code 13922-4…………………………………………………………………………………..T5-5-91
Monitor Controller (Monitor) Fault Code 13943-2…………………………………………………………………………………..T5-5-91
Monitor Controller (Monitor) Fault Code 13944-2…………………………………………………………………………………..T5-5-92
Monitor Controller (Monitor) Fault Code 13951-2…………………………………………………………………………………..T5-5-93
Monitor Controller (Monitor) Fault Code 13991-2…………………………………………………………………………………..T5-5-93
Monitor Controller (Monitor) Fault Code 13992-2…………………………………………………………………………………..T5-5-94
Switch Box Controller Fault Code 14504-3……………T5-5-94
Switch Box Controller Fault Code 14504-4……………T5-5-95
Aerial Angle Controller Fault Code 68000-2………….T5-5-95
Aerial Angle Controller Fault Code 68001-2………….T5-5-96
Aerial Angle Controller Fault Code 68002-2………….T5-5-96
Aerial Angle Controller Fault Code 73022-2………….T5-5-97
Aerial Angle Controller Fault Code 68003-2………….T5-5-98
PLCU Fault Code 53007-3…………………………………………T5-5-98
PLCU Fault Code 53007-4…………………………………………T5-5-99
PLCU Fault Code 53008-3…………………………………………T5-5-99
PLCU Fault Code 53008-4………………………………………T5-5-100
PLCU Fault Code 53009-12……………………………………T5-5-101
PLCU Fault Code 53009-7………………………………………T5-5-101
PLCU Fault Code 53010-12……………………………………T5-5-101
PLCU Fault Code 53010-7………………………………………T5-5-102
PLCU Fault Code 53011-2………………………………………T5-5-102
PLCU Fault Code 53011-6………………………………………T5-5-103
PLCU Fault Code 53011-5………………………………………T5-5-103
PLCU Fault Code 53012-2………………………………………T5-5-104
PLCU Fault Code 53012-6………………………………………T5-5-104
PLCU Fault Code 53012-5………………………………………T5-5-105
PLCU Fault Code 53013-2………………………………………T5-5-106
PLCU Fault Code 53013-6………………………………………T5-5-106
PLCU Fault Code 53013-5………………………………………T5-5-107
PLCU Fault Code 53014-2………………………………………T5-5-108
PLCU Fault Code 53014-6………………………………………T5-5-108
PLCU Fault Code 53014-5………………………………………T5-5-109
PLCU Fault Code 53017-2………………………………………T5-5-109
PLCU Fault Code 53018-2………………………………………T5-5-110
PLCU Fault Code 53019-2………………………………………T5-5-110
PLCU Fault Code 53020-2………………………………………T5-5-110
PLCU Fault Code 53021-2………………………………………T5-5-111
PLCU Fault Code 53009-8………………………………………T5-5-111
PLCU Fault Code 53010-8………………………………………T5-5-111
PLCU Fault Code 53017-8………………………………………T5-5-112
PLCU Fault Code 53020-8………………………………………T5-5-112
PLCU Fault Code 53018-8………………………………………T5-5-112
PLCU Fault Code 53021-8………………………………………T5-5-112
PLCU Fault Code 63001-3………………………………………T5-5-113
PLCU Fault Code 63001-4………………………………………T5-5-114
PLCU Fault Code 73023-2………………………………………T5-5-115
PLCU Fault Code 73024-2………………………………………T5-5-115
PLCU Fault Code 73035-7………………………………………T5-5-115
Power-CAN harness Check……………………………………T5-5-116
Body-CAN Harness Check……………………………………..T5-5-117
ISO-CAN (Engine) Harness Check………………………..T5-5-119
TTDD750-EN-00(22/01/2020)
IF-CAN Harness Check……………………………………………T5-5-121
OPT-CAN Harness Check……………………………………….T5-5-122
PL-CAN Harness Check………………………………………….T5-5-123
ECM Fault Code List………………………………………………..T5-5-124
DCU Fault Code List……………………………………………….T5-5-134
Troubleshooting B………………………………T5-6-1
Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure………………………………T5-6-1
Contents of Troubleshooting B…………………………………T5-6-1
Relationship between Machine Trouble Symptoms and Related Parts……………………………….T5-6-3
When a Fault Occurs in MC (Main Controller)…………T5-6-3
When a Fault Occurs in Switch Box Controller……….T5-6-3
When a Fault Occurs in Engine Control Dial…………..T5-6-3
When a Fault Occurs in Auto-Idle Switch………………..T5-6-4
When a Fault Occurs in Power Mode Switch………….T5-6-4
When a Fault Occurs in Travel Mode Switch…………..T5-6-5
When a Fault Occurs in Power Digging Switch………T5-6-5
When a Fault Occurs in Pilot Shut-Off Shut-OffShut-OffShut-Off Switch (Pilot Shut-Off Shut-OffShut-OffShut-Off Lever)……………………………………………………….T5-6-5
When a Fault Occurs in Manual Regeneration Switch………………………………………………………………………T5-6-6
When a Fault Occurs in Aerial Angle Switch…………..T5-6-6
When a Fault Occurs in Pilot Shut-Off Shut-OffShut-OffShut-Off Solenoid Valve…………………………………………………………………………T5-6-7
When a Fault Occurs in Hydraulic Oil Temperature Sensor………………………………………………………………………T5-6-7
When a Fault Occurs in Differential Differential Differential Pressure Sensor………………………………………………………………………T5-6-7
When a Fault Occurs in DOC Inlet Exhaust Temperature Sensor………………………………………………T5-6-8
When a Fault Occurs in DOC Outlet Exhaust Temperature Sensor………………………………………………T5-6-8
When a Fault Occurs in SCR Exhaust Temperature Sensor………………………………………………………………………T5-6-8
When a Fault Occurs in Pump 1 Delivery Pressure Sensor………………………………………………………………………T5-6-9
When a Fault Occurs in Pump 2 Delivery Pressure Sensor………………………………………………………………………T5-6-9
When a Fault Occurs in Pump 3 Delivery Pressure Sensor………………………………………………………………………T5-6-9
When a Fault Occurs in Pump 1 Control Pressure Sensor…………………………………………………………………….T5-6-10
When a Fault Occurs in Pump 2 Control Pressure Sensor…………………………………………………………………….T5-6-10
When a Fault Occurs in Pump 3 Control Pressure Sensor…………………………………………………………………….T5-6-10
When a Fault Occurs Swing Pilot Pressure Sensor…………………………………………………………………………………..T5-6-11
When a Fault Occurs in Boom Raise Pilot Pressure Sensor…………………………………………………………………….T5-6-11
When a Fault Occurs in Arm 2 Roll-In Pilot Pressure Sensor…………………………………………………….T5-6-11
When a Fault Occurs in Arm 1 Roll-In Pilot Pressure Sensor…………………………………………………….T5-6-12
When a Fault Occurs in Travel Pilot Pressure Sensor…………………………………………………………………….T5-6-12
When a Fault Occurs in Front Pilot Pressure Sensor…………………………………………………………………………………T5-6-12
When a Fault Occurs in Bucket Roll-In Pilot Pressure Sensor…………………………………………………….T5-6-13
When a Fault Occurs in Arm Roll-Out Pilot Pressure Sensor…………………………………………………….T5-6-13
When a Fault Occurs in Bucket Roll-Out Pilot Pressure Sensor…………………………………………………….T5-6-13
When a Fault Occurs in Auxiliary 1 Pilot Pressure Sensor (Option)…………………………………………………….T5-6-14
When a Fault Occurs in Auxiliary 2 Pilot Pressure Sensor (Option)…………………………………………………….T5-6-14
When a Fault Occurs in Pump 1 and 2 Torque Control Solenoid Valve………………………………………..T5-6-15
When a Fault Occurs in Pump 3 Torque Control Solenoid Valve………………………………………………………T5-6-15
When a Fault Occurs in Maximum Pump 1 Flow Rate Limit Control Solenoid Valve……………………..T5-6-15
When a Fault Occurs in Maximum Pump 2 Flow Rate Limit Control Solenoid Valve……………………..T5-6-16
When a Fault Occurs in Maximum Pump 3 Flow Rate Limit Control Solenoid Valve……………………..T5-6-16
When a Fault Occurs in 5-Spool Solenoid Valve Unit (SI)…………………………………………………………………..T5-6-17
When a Fault Occurs in 5-Spool Solenoid Valve Unit (SD)…………………………………………………………………T5-6-17
When a Fault Occurs in 5-Spool Solenoid Valve Unit (SE)…………………………………………………………………T5-6-18
When a Fault Occurs in 5-Spool Solenoid Valve Unit (SF)………………………………………………………………….T5-6-18
When a Fault Occurs in 5-Spool Solenoid Valve Unit (SC)…………………………………………………………………T5-6-18
When a Fault Occurs in 3-Spool Solenoid Valve Unit (SK1)……………………………………………………………….T5-6-19
When a Fault Occurs in 3-Spool Solenoid Valve Unit (SK2)……………………………………………………………….T5-6-19
When a Fault Occurs in 3-Spool Solenoid Valve Unit (SK3)……………………………………………………………….T5-6-20
When a Fault Occurs in 2-Spool Solenoid Valve Unit (SZ)…………………………………………………………………T5-6-20
When a Fault Occurs in 2-Spool Solenoid Valve Unit (SJ)………………………………………………………………….T5-6-21
When a Fault Occurs in Main Relief Valve (For P1, P2)…………………………………………………………………………..T5-6-21
When a Fault Occurs in Main Relief Valve (For P3)…………………………………………………………………………………..T5-6-22
When a Fault Occurs in Overload Relief Valve………T5-6-22
When a Fault Occurs in Boom Anti-Drift Valve……..T5-6-22
When a Fault Occurs in Arm Rod Anti-Drift Valve……………………………………………………………………………………T5-6-23
When a Fault Occurs in Arm Bottom Anti-Drift Valve……………………………………………………………………….T5-6-23
When a Fault Occurs in Flow Combiner Valve………T5-6-24
TTDD750-EN-00(22/01/2020)
When a Fault Occurs in Boom Regenerative Valve………………………………………………………………………………….T5-6-24
When a Fault Occurs in Arm Regenerative Valve…………………………………………………………………………………….T5-6-24
When a Fault Occurs in Bucket Regenerative Valve…………………………………………………………………………………T5-6-25
When a Fault Occurs in Bucket Regeneration Cut Valve……………………………………………………………………….T5-6-25
When a Fault Occurs in Arm 1 Flow Rate Control Valve……………………………………………………………………….T5-6-25
When a Fault Occurs in Auxiliary Flow Combiner Valve……………………………………………………………………….T5-6-26
When a Fault Occurs in Pump 1 Bypass Shut-Out Valve……………………………………………………………………….T5-6-26
When a Fault Occurs in Pump 3 Bypass Shut-Out Valve……………………………………………………………………….T5-6-27
When a Fault Occurs in Digging Regenerative Valve……………………………………………………………………….T5-6-27
When a Fault Occurs in Boom Lower Meter-In Cut Valve……………………………………………………………………….T5-6-28
When a Fault Occurs in Arm Roll-In Meter-Out Open Control Spool……………………………………………..T5-6-28
When a Fault Occurs in Travel Motor Displacement Angle Control Valve……………………T5-6-29
When a Fault Occurs in Pump 1 Flow Rate Control Valve……………………………………………………………………….T5-6-29
When a Fault Occurs in Pump 2 Flow Rate Control Valve……………………………………………………………………….T5-6-30
When a Fault Occurs in Pump 3 Flow Rate Control Valve……………………………………………………………………….T5-6-30
When a Fault Occurs in Swing Parking Brake Release Spool………………………………………………………..T5-6-31
When a Fault Occurs in Flow Combiner Valve Control Spool………………………………………………………..T5-6-31
When a Fault Occurs in Auxiliary Flow Combiner Control Solenoid Valve (Option)………………………..T5-6-32
When a Fault Occurs in Selector Valve Control Solenoid Valve (Option)………………………………………T5-6-32
When a Fault Occurs in Selector Valve (Option)…..T5-6-32
When a Fault Occurs in Accumulator Control Valve (Option)……………………………………………………….T5-6-33
When a Fault Occurs in Breaker Relief Solenoid Valve (Option)……………………………………………………….T5-6-33
When a Fault Occurs in Auxiliary Overload Relief Solenoid Valve (Option)………………………………………T5-6-33
Identification Identification Symbol of Troubleshooting B…………T5-6-34
Correlation between Trouble Symptoms and Part Failures…………………………………………………………………..T5-6-35
Parts Related with “E-1 Starter does not rotate.”….T5-6-35
Parts Related with “E-2 Even if starter rotates, engine does not start.”…………………………………………T5-6-35
Parts Related with “E-3 Even if power mode switch is operated, power mode is not shifted.”…………………………………………………………………………………T5-6-35
Parts Related with “E-4 ECO mode is faulty.”…………T5-6-36
Parts Related with “E-5 Travel HP mode is faulty.”……………………………………………………………………………………T5-6-36
Parts Related with “E-6 Auto-idle system is faulty.”…………………………………………………………………………………T5-6-36
Parts Related with “E-7 Even if pilot shut-off shut-offshut-off lever is set to UNLOCK position with engine running at slow idle speed, engine speed does not increase.”………………………………………………………………..T5-6-37
Parts Related with “E-8 Engine speed does not increase when coolant temperature is low.”…….T5-6-37
Parts Related with “E-9 Auto shut-down is not activated.”………………………………………………………………T5-6-37
Parts Related with “E-12 Engine speed does not decrease when audio mute/one-touch idle switch is pushed.”…………………………………………………T5-6-38
Parts Related with “A-1 All actuators do not work.”…………………………………………………………………………………T5-6-38
Parts Related with “A-2 All actuator speeds are slow.”………………………………………………………………………T5-6-38
Parts Related with “A-3 Actuator does not stop even if control lever is set to neutral.”……………….T5-6-39
Parts Related with “A-4 Manual regeneration of aftertreatment device cannot be performed.”…………………………………………………………………………………….T5-6-39
Parts Related with “A-5 Travel (right) operation speed is slow when performing travel single operation. Bucket single operation speed is slow. (All problems occur at the same time.)”….T5-6-40
Parts Related with “A-6 Travel (left) operation speed is slow when performing travel single operation. Attachment single operation speed is slow. (All problems occur at the same time.)”………………………………………………………………………………….T5-6-40
Parts Related with “A-9 Swing single operation speed is slow. Boom speed is slightly slow when performing arm level crowding operation. (All problems occur at the same time.)”…………………………………………………………………….T5-6-40
Parts Related with “F-1 All front attachment actuator powers are weak.”…………………………………T5-6-40
Parts Related with “F-2 Front attachment drifts remarkably.”…………………………………………………………..T5-6-41
Parts Related with “F-3 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.”……………………T5-6-41
Parts Related with “F-4 Even if power digging switch is pushed, power does not increase. Boom raise power is weak when performing digging operation.”………………………………………………T5-6-41
Parts Related with “F-5 Boom, arm, or bucket single operation is not operated. Boom, arm, or bucket single operation speed is slow.”……………T5-6-42
Parts Related with “F-6 Bucket roll-in speed is slow or power is weak when performing digging operation.”……………………………………………………………..T5-6-42
TTDD750-EN-00(22/01/2020)
Parts Related with “F-7 When performing combined operation, arm does not start to move smoothly. Arm starts to move slightly slow when performing arm single operation. These troubles often occur when temperature is low.”…………………………………………………………………….T5-6-43
Parts Related with “F-8 When performing combined operation, boom does not start to move smoothly. Boom starts to move slightly slow when performing boom lower single operation.”……………………………………………………………..T5-6-43
Parts Related with “F-9 Boom lower speed above ground is faster than other actuators when performing combined operation. Machine cannot be raised off the ground.”………………………T5-6-43
Parts Related with “F-10 Arm roll-in speed is slow when performing digging operation.”……………..T5-6-43
Parts Related with “F-11 Arm roll-in speed is fast when performing arm level crowding operation. Arm power is weak when performing digging operation.”…………………………T5-6-44
Parts Related with “F-14 Boom raise or attachment speed is slow when performing combined operation of boom raise and arm or attachment and arm.”………………………………………….T5-6-44
Parts Related with “F-16 Boom raise speed is slow when performing combined operation of swing and boom raise.”……………………………………….T5-6-45
Parts Related with “F-22 Bucket speed is slow when performing combined operation of arm roll-in and bucket. Boom raise speed is slow when performing combined operation of swing, boom raise, and arm roll-in. Arm roll-in speed is slow.”……………………………………………………….T5-6-45
Parts Related with “F-23 Arm roll-out speed is slow.”………………………………………………………………………T5-6-46
Parts Related with “F-24 Arm roll-in speed is slow when performing combined operation of boom raise and arm roll-in.”……………………………….T5-6-46
Parts Related with “S-1 Swing speed is slow or is not operated.”……………………………………………………….T5-6-46
Parts Related with “S-2 When starting swing operation, swing speed is fast.”………………………….T5-6-47
Parts Related with “T-1 Both of right and left travels are not operated or travel speed is slow.”………………………………………………………………………T5-6-47
Parts Related with “T-2 One side travel is not operated or travel speed is slow. Machine mistracks.”………………………………………………………………T5-6-47
Parts Related with “T-3 Machine mistracks when performing combined operation of travel and front attachment.”………………………………………………..T5-6-48
Parts Related with “T-4 Fast travel can not be selected. Travel mode does not change from slow speed mode to fast speed mode.”…………….T5-6-48
Parts Related with “T-5 Occasionally, machine may mistrack when traveling with engine running at slow speed.”………………………………………………………T5-6-48
Parts Related with “T-6 Attachment speed is slow when performing attachment single operation. Travel speed is slow when performing combined operation of attachment and travel.”…………………………………………………………………………………T5-6-49
Parts Related with “O-1 Work light does not light.”…………………………………………………………………………………T5-6-49
Parts Related with “O-2 Cab light does not light.”……………………………………………………………………………………T5-6-49
Parts Related with “O-3 Wiper is not operated.”…..T5-6-50
Parts Related with “O-4 Washer is not operated.”……………………………………………………………………………………T5-6-50
Parts Related with “O-5 Boom light does not light.”………………………………………………………………………T5-6-50
Parts Related with “O-6 Camera image does not change when aerial angle switch is pressed.”….T5-6-50
E-1 Starter does not rotate………………………………………T5-6-51
E-2 Even if starter rotates, engine does not start…………………………………………………………………………………….T5-6-52
E-3 Even if power mode switch is operated, power mode is not shifted………………………………………………T5-6-53
E-4 ECO mode is faulty……………………………………………..T5-6-53
E-5 Travel HP mode is faulty…………………………………….T5-6-53
E-6 Auto-idle system is faulty………………………………….T5-6-54
E-7 Even if pilot shut-off shut-offshut-off lever is set to UNLOCK position with engine running at slow idle speed, engine speed does not increase……………T5-6-55
E-8 Engine speed does not increase when coolant temperature is low……………………………………………….T5-6-55
E-9 Auto shut-down is not activated……………………..T5-6-55
E-12 Engine speed does not decrease when audio mute/one-touch idle switch is pushed…………….T5-6-56
A-1 All actuators do not work………………………………….T5-6-56
A-2 All actuator speed are slow………………………………T5-6-58
A-3 Actuator does not stop even if control lever is set to neutral…………………………………………………………T5-6-58
A-4 Manual regeneration of aftertreatment device cannot be performed…………………………………………..T5-6-59
A-5 Travel (right) operation speed is slow when performing travel single operation. Bucket single operation speed is slow. (All problems occur at the same time.)……………………………………..T5-6-60
A-6 Travel (left) operation speed is slow when performing travel single operation. Attachment single operation speed is slow. (All problems occur at the same time.)……………………T5-6-60
A-9 Swing single operation speed is slow. Boom speed is slightly slow when performing arm level crowding operation. (All problems occur at the same time.)…………………………………………………T5-6-60
F-1 All front attachment actuator powers are weak……………………………………………………………………….T5-6-61
F-2 Front attachment drifts remarkably…………………T5-6-61
TTDD750-EN-00(22/01/2020)
F-3 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down………………………………………………………..T5-6-62
F-4 Even if power digging switch is pushed, power does not increase. Boom raise power is weak when performing digging operation……..T5-6-63
F-5 Boom, arm, or bucket single operation is not operated. Boom, arm, or bucket single operation speed is slow………………………………………T5-6-63
F-6 Bucket roll-in speed is slow or power is weak when performing digging operation………………..T5-6-64
F-7 When performing combined operation, arm does not start to move smoothly. Arm starts to move slightly slow when performing arm single operation. These troubles often occur when temperature is low…………………………………….T5-6-65
F-8 When performing combined operation, boom does not start to move smoothly. Boom starts to move slightly slow when performing boom lower single operation………………………………………..T5-6-65
F-9 Boom lower speed above ground is faster than other actuators when performing combined operation. Machine cannot be raised off the ground…………………………………………..T5-6-65
F-10 Arm roll-in speed is slow when performing digging operation………………………………………………..T5-6-66
F-11 Arm roll-in speed is fast when performing arm level crowding operation. Arm power is weak when performing digging operation……..T5-6-66
F-14 Boom raise or attachment speed is slow when performing combined operation of boom raise and arm or attachment and arm…..T5-6-67
F-16 Boom raise speed is slow when performing combined operation of swing and boom raise…………………………………………………………………………………..T5-6-67
F-22 Bucket speed is slow when performing combined operation of arm roll-in and bucket. Boom raise speed is slow when performing combined operation of swing, boom raise, and arm roll-in. Arm roll-in speed is slow…………………T5-6-67
F-23 Arm roll-out speed is slow………………………………T5-6-67
F-24 Arm roll-in speed is slow when performing combined operation of boom raise and arm roll-in………………………………………………………………………T5-6-68
S-1 Swing speed is slow or is not operated…………..T5-6-68
S-2 When starting swing operation, swing speed is fast………………………………………………………………………T5-6-69
T-1 Both of right and left travels are not operated or travel speed is slow………………………………………….T5-6-69
T-2 One side travel is not operated or travel speed is slow. Machine mistracks………………………………….T5-6-70
T-3 Machine mistracks when performing combined operation of travel and front attachment……………………………………………………………T5-6-71
T-4 Fast travel can not be selected. Travel mode does not change from slow speed mode to fast speed mode…………………………………………………………..T5-6-71
T-5 Occasionally, machine may mistrack when traveling with engine running at slow speed……………………………………………………………………………………..T5-6-72
T-6 Attachment speed is slow when performing attachment single operation. Travel speed is slow when performing combined operation of attachment and travel…………………………………………T5-6-73
O-1 Work light does not light………………………………….T5-6-73
O-2 Cab light does not light…………………………………….T5-6-74
O-3 Wiper is not operated……………………………………….T5-6-74
O-4 Washer is not operated…………………………………….T5-6-75
O-5 Boom light does not light………………………………..T5-6-76
O-6 Camera image does not change when aerial angle switch is pressed………………………………………..T5-6-76
Exchange Inspection………………………………………………..T5-6-77
How to Lower Boom in Case of Emergency and When Engine Stops without Hose Rupture Valve……………………………………………………………………….T5-6-81
How to Lowering Boom When Emergency and When Engine Stops with Hose Rupture Valve…………………………………………………………………………………….T5-6-82
Attachment Circuit Pressure Release Procedure….T5-6-82
Air Conditioner…………………………………..T5-7-1
Outline of Air Conditioner…………………………………………T5-7-1
Component Layout of Air Conditioner……………………T5-7-2
Functions of Main Electrical Parts…………………………….T5-7-4
Troubleshooting of Air Conditioner…………………………T5-7-7
Monitor Controller (Monitor) Fault Code 13911-3…………………………………………………………………………………….T5-7-8
Monitor Controller (Monitor) Fault Code 13912-4…………………………………………………………………………………….T5-7-8
Monitor Controller (Monitor) Fault Code 13913-3…………………………………………………………………………………….T5-7-9
Monitor Controller (Monitor) Fault Code 13914-4…………………………………………………………………………………..T5-7-10
Monitor Controller (Monitor) Fault Code 13917-3…………………………………………………………………………………..T5-7-10
Monitor Controller (Monitor) Fault Code 13918-4…………………………………………………………………………………..T5-7-11
Monitor Controller (Monitor) Fault Code 13921-3…………………………………………………………………………………..T5-7-11
Monitor Controller (Monitor) Fault Code 13922-4…………………………………………………………………………………..T5-7-12
Monitor Controller (Monitor) Fault Code 13943-2…………………………………………………………………………………..T5-7-12
Monitor Controller (Monitor) Fault Code 13944-2…………………………………………………………………………………..T5-7-13
Monitor Controller (Monitor) Fault Code 13951-2…………………………………………………………………………………..T5-7-14
Monitor Controller (Monitor) Fault Code 13991-2…………………………………………………………………………………..T5-7-14
TTDD750-EN-00(22/01/2020)
Monitor Controller (Monitor) Fault Code 13992-2…………………………………………………………………………………..T5-7-15
Faulty Cooling (1)………………………………………………………T5-7-16
Faulty Cooling (2)………………………………………………………T5-7-17
Faulty Cooling (3)………………………………………………………T5-7-18
Faulty Cooling (4)………………………………………………………T5-7-20
Faulty Cooling (5)………………………………………………………T5-7-21
Faulty Heating (1)………………………………………………………T5-7-23
Faulty Heating (2)………………………………………………………T5-7-24
Others…………………………………………………………………………T5-7-24
Blower motor does not operate……………………………..T5-7-25
Compressor clutch does not operate…………………….T5-7-26
Cooling Circuit Check by Using Manifold Gauge…………………………………………………………………………………….T5-7-28
Work after Replacing Components………………………..T5-7-31
RefillRefill compressor oil………………………………………………….T5-7-32
Necessity of Purging…………………………………………………T5-7-32
Procedures for Charging Air Conditioner with Refrigerant…………………………………………………………….T5-7-34
Warm-Up Operation…………………………………………………T5-7-39
Hose and Pipe Tightening Torque………………………….T5-7-41
Description:
Kawasaki Wheel Loader ZX350 7 Operational & Service Manual & Parts Manual
- To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
●
Be sure to thoroughly read this manual for correct product information and service procedures.
●
If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy this form for usage.)
•
Service Material Development Center Hitach Construction Machinery Co., Ltd.
•
TEL: 81-29-832-9673
•
FAX: 81-29-831-1162
•
E-mail: [email protected]
All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
●
Information included in the Technical Manual: Technical information needed for redelivery and delivery
•
Operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
●
Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine
•
Tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures
●
Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine
•
Operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures
Please Note:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]